Methods and devices for manufacturing of electrical components and laminated structures

ABSTRACT

A method and device for manufacturing of electrical components on a continuous web or discrete sheets of dielectric material are disclosed. The method includes feeding, from a supply roll of a laminated web or a supply of sheets including at least one unbroken layer of conducting material laminated on a flexible backing layer of dielectrical material, the laminated web or discrete sheets to a nip between a patterned cylinder and a cooperating cylinder, to shape the conducting layer into a repeated pattern of conducting material having ridges and valleys. The method further includes removing, by mechanical machining, conducting material from the thus shaped conducting layer. The removing is performed simultaneously with the step to shape the conducting layer, and by way of the cooperating cylinder, designed as a milling cutter cylinder.

FIELD OF THE INVENTION

Present invention is directed to a method for manufacturing ofelectrical components on a continuous web of dielectric material ordiscrete sheets, including the step to feed, from a supply roll of alaminated web or a supply of sheets consisting of at least one layer ofconducting material laminated on a flexible backing layer ofdielectrical material, said laminated web or discrete sheets to a nipbetween a patterned cylinder and a cooperating cylinder to shape saidconducting layer into a repeated pattern of conducting material havingridges and valleys, and the step to remove by mechanical machiningconducting material from said thus shaped metal layer. It is alsodirected to a device for manufacturing of said electrical components.

More specifically, present invention concerns a method and a device forremoving parts of one or more outer layer(-s) from a web or a sheethaving a number of layers, at least one layer exhibiting good electricalconductivity and at least one layer is made of electrical insulatingmaterial or dielectric material. The method and device according topresent invention is especially well suited for manufacturing ofelectrical conductors and components on a flexible backing, such aspaper or plastic film.

In a more general perspective, the invention is directed to a method anda device for patterning a laminated sheet, to a cliché used in such amethod and device, to a cliché blank for providing the cliché, to alaminated sheet patterned by such a method and device and to a printingsystem comprising such a device.

TECHNICAL BACKGROUND

It is previously known to manufacture electrical conductors andcomponents on flexible backings or carriers by firstly apply a thinlayer (<1 mm) of conducting material on the backing, e.g. metal or metalalloy or doped resin material, and secondly remove not wanted parts ofsaid layer from the backing by etching with chemical substances. Adrawback inherent in this kind of technique is that the process has tobe done in a number of separate steps and thus it is only possible toperform this technique in a continuous process if the feeding rate ofthe web is low. An other problem is the possibility of unsufficientetching (when the process is isotropic). Further, the employed chemicalsubstances give risk to waste management problems and high environmentalloads.

Besides, it is previously known to remove thin layers from multilayeredflexible material by milling, e.g. when perforating stamps. It is alsoknown to measure the distance between two rolls forming a nip, throughwhich a web of high resistivity is passed, by applying a voltage overthe rolls. The measured resistance is decisive of said distance.

U.S. Pat. No. 6,083,837 illustrates a method and a device foruninterrupted manufacturing of electrical components. A metal sheet ispassed through a nip between an embossing roller and an anvil deformingthe metal sheet into a repeated pattern consisting of thick and thinregions. Downstream said nip a dielectric base material is applied tothe thus deformed metal sheet and the assembly is fed to a processstation where the thin metal regions are removed by etching, sputteringor abrading. Then the produced electrical components supported by saidcarrier of dielectric material are supplied to further process station.This known process requires a number of process stations and deformsrather than shapes the metal layer. Thus, the distance between the rolland the anvil is not critical and there is no means provided to adjustthe size of nip. Further, the carrier material has to be flowable toadapt to the embossed metal layer.

SUMMARY OF THE INVENTION

It is an object of present invention to provide a method and devicefacilitating manufacturing of electrical components in a fast andreliable way using a single step.

It is an other object of present invention to manufacture electricalcomponents on a continuous web or discrete sheets of an inexpensive andeasy-to-handle material.

A further object of present invention is to manufacture electricalcomponents on a continuous web allowing winding to a roll, facilitatingstoring and shipping and further processing of the electricalcomponents.

These and other objects of present invention have been achieved by amethod according to the first paragraph, characterized in that the stepto remove conducting material from said conducting layer is performedsimultaneously with the step to shape the conducting layer and by meansof said cooperating cylinder designed as a milling cutter cylinder.

In this context, “simultaneously” means that the milling takes placewhile there is still sufficient support (such as by the ridges of thecliché) provided for the ridges created by the patterned cylinder.Hence, the actual forming of the ridges and valleys may take placeslightly before the cutting operation, as long as there is stillsufficient support for the ridges whose material is to be cut away, whenthe cutting takes place. For example, the shaping may begin at themoment the web or sheet sufficiently contacts the patterned cylinder,whereas a small period of time passes between such first contact and thecutting operation. During such time, the patterned cylinder may rotateso as to bring the web or sheet from the angular position of firstcontact (and start of the shaping operation) to the angular positionwhere the cutting is effected. According to another aspect of theinvention, what is referred to as a conducting layer above may be anytype of functional layer.

The term “functional layer” is intended to comprise layers having atechnical function, different than that of the backing layer, such asproviding adhesiveness, swelling or shape altering properties (i.e.materials comprising blowing agents, memory alloys or similar), thermalexpansion or shrinking properties, biocompatible properties, electricalor optical conductivity, semi-conductivity, semi-metallic materials,dielectric materials, alteration in surface energy (wettability) etc.

A device to perform said method according to present invention ischaracterized in that said rotating anvil is configurated as a millingcutter cylinder to remove conducting material from said metal layersimultaneously as the conducting layer is forced against the patternedcylinder to shape said repeated pattern.

The invention is defined in the appended independent claims.

Embodiments of the invention are set forth in the subclaims, in thefollowing description and in the drawings.

Present invention is based on the recognition that it is possible toremove material, and in particular conducting material, from a web ordiscrete sheets by milling instead of etching when manufacturingelectrical components on a coated flexible carrier substrate. The coatedsubstrate is passed through a nip between two rotating rolls orcylinders. One of the rolls is equipped with milling elements or thelike and the other roll is a kind of cliché roll or die cylinder havinga pattern engraved into its envelope surface. The regions in which theconducting or metal layer is to be removed are present in the envelopesurface and the regions in which the conducting layer are to beretained, completely or partly, are the engraved or recessed areas ofthe cliché roll. When passing through the nip the web or the discretesheets is (are) forced against the cliché roll by applying a tensilestress on the running web or the discrete sheets and the relevant partsof the conducting layer are removed by milling without perforating thecarrier substrate. However, it is possible to partly or totallyperforate the carrier substrate, if needed.

A condition for making above stated method work is that is it possibleto precisely enough measure how much material that is removed from thecoating by the milling elements, i.e. the distance between the tips ofthe milling elements and the envelope surface of the cliché roll orpatterned cylinder. A way to decide this is to isolate every machinepart that will contact said conducting layer or carrier substrate andmeasure the resistance of the carrier substrate. From the rate of theresistance it is possible to determine the thickness of the layer. Dueto the high resistivity of the carrier substrate the modification of thelayer thickness (i.e. how much material that is removed) will be hard tomeasure by this technique. Further, the measurements are influenced byexternal conditions like air humidity, metal debris etc.

Alternately, said measurements may be conducted indirectly, at aposition along the travel path just downstream said nip. A conditiontherefore is that one or more reference rings are embossed, etched orengraved in the envelope surface of the cliché roll, preferably outsidethe useful patterning region. However, it is also possible to arrangeone or more of said rings somewhere between the ends of the cliché rollprovided that they do not interfere with the electrical components to beproduced. According to one embodiment two rings are provided at each endof the roll, one having a radius r₁ and the other a radius r₂ while theenvelope surface of said roll has a radius r_(e), where r_(e)≧r₁>r₂.Sensor means using per se known reading technique by means ofphoto-electric tubes or photo cells, e.g., are arranged along the travelpath of the web, just downstream the nip, detecting the tracks in theconducting layer made by said rings in cooperation with the millingelements. Preferably, the radii of the reference rings are chosen suchthat-only the track relating to the first ring will appear if saiddistance is correct. If the distance is too large there will be no trackfrom the first ring and if the distance is to small the track from thesecond ring will appear too.

An advantage of the above method, as compared to etching techniques, isthat the substrate (i.e. the web or sheet) does not need to become wet.This is particularly advantageous if one desires to use an absorbingmaterial such as paper as carrier material. Furthermore, no residues ofthe chemicals used are left on any of the processed or unprocessedsurfaces.

BRIEF DESCRIPTION OF THE DRAWINGS

A preferred embodiment of present invention is illustrated below withreference to the accompanying drawings, in which:

FIG. 1 schematically and in a perspective view illustrates the principleof the invention;

FIG. 2 in a top view, with the web removed upstream the nip forillustration purposes, shows the device of FIG. 1 and formed referencetracks (but not the associated sensor means);

FIG. 3 in a side view diagrammatically shows a presently preferredembodiment of the invention;

FIG. 4 in an enlarged scale illustrates a part of the envelope surfaceof the patterned cylinder or cliché roll when the web is entering thenip between said cylinder and the cutter cylinder (not shown), justbefore initiating of the milling action of the conducting layer of theweb;

FIG. 5 in a view identical to that of FIG. 4 specifically shows the webafter relevant parts of the conducting layer accurately have beenremoved and the backing layer or carrier substrate is substantiallynon-affected;

FIG. 6 in a top view schematically illustrates the processed web of FIG.5 and the metalless tracks over the first reference rings, andassociated sensor means;

FIG. 7 in a view identical to that of FIGS. 4 and 5 specifically showsthe web after having passed a too small nip and, thus, a thickness ofthe backing layer has been removed too; and

FIG. 8 in a view identical to that of FIG. 6 schematically illustratesthe processed web of FIG. 7 and the metalless tracks over the first aswell as the second reference rings and associated sensor means.

FIG. 9 a-9 b are schematic perspective views of alternative controlpatterns.

FIG. 10 a-10 c are schematic sectional views of a web in a planesubstantially perpendicular to a main plane.

FIG. 11 is a schematic close-up sectional view of a web on a patternedcylinder, wherein surface portions of an upper layer have been removed.

DESCRIPTION OF EMBODIMENTS

Referring first to FIGS. 1, 2 and 4 a continuous web 1 consisting of atleast one layer 2 of a conducting material, e.g. metal or metal alloy orconducting polymer, and a flexible backing or carrier layer 3 ofdielectric material is fed from a supply roll 4, via a support roll 5 toa nip 6. The layer 2 of conducting material is preferably a continuouslayer, but it can also be a discontinuous layer consisting of two ormore parallel strips oriented in the feeding direction of the web. It isalso possible to arrange the layer 2 as discrete areas of conductingmaterial. The backing 3, preferably a plastic (PET) foil or paper, has amore or less consistent thickness t, while the conducting layer 2 may bevarying in thickness. The gauges of the different layers are varying,the conducting layer being <1 mm and the backing layer (t) being <1 mm.As will be recognized by a man skilled in the art discrete sheets fedfrom a supply or storage (not illustrated) may be used instead of saidcontinuous web provided that they are designed like said web.

The web 1 is advanced to and through the nip 6 defined by a cliché rollor patterned cylinder 7 like an embossing cylinder and a milling cuttercylinder 8 having a plurality of milling elements 9 on its cylindricalsurface. The term “milling cutter” is meant to include all rotatingbodies having an abrading, abrasive or milling envelope surface equippedwith teeth, grit or abrasive grains of, for example, sand, diamondparticles or similar. The running web is forced against the envelopesurface 11 of the patterned cylinder 7, by applying a tensile stress onthe running web 1 in a way known by a man skilled in the art, e.g. bymeans of a support roll 17 arranged to press the web 1 towards thepatterned cylinder 7, and into recesses 12 engraved or etched in saidsurface 11. Thus, the metal layer 2 is shaped into a repeatedthree-dimensional pattern of ridges 13 (over the remaining originalregions of the envelope surface 11) and of valleys 14 (over the recesses12 processed into the envelope surface 11). When being of a paper layerthe backing 3 assumes the same pattern as the metal layer 2. The cuttercylinder 8 acts as a milling or abrading tool and mills or abrades theouter layer, i.e. the metal layer 2, simultaneously or almostsimultaneously with said shaping of the web. The patterned cylinder 7rotates at a periphery velocity equal to the feeding velocity of the web1, and the cutter cylinder rotates at a much higher periphery velocity.In the milling step electrical components 15 are manufactured on the web1. The rotation direction of the cutter cylinder is contrary to therotation direction of the patterned cylinder but this rotationrelationship is arbitrary, i.e. said cylinders may rotate in the samedirection but with different periphery speeds. After passing throughsaid nip 6 and having been milled or abraded the processed web 10 iswound to a roll 16 of electrical components on a continuous web ofdielectrical material (3) via a support roll 17 for further processing.Alternately, a cutting device (not shown) cuts the processed web 10 intosheets.

In one embodiment, the patterned cylinder 7 is formed as a metal plate,which may be made from a magnetic material (e.g. steel) so that it canbe magnetically attached to a carrying cylinder. The cliché can beformed by etching, spark machining, abrasive blasting and/or milling.

In an alternative embodiment, the cliché may have a surface layer of aformable material, such as an un-cured polymer material, whereby formingcomprises exposing the formable material to e.g. UV light, for curingexposed portions, after which uncured portions are removed such as tocreate a relief pattern. Such a cliché may also have a base of steel, sothat it can be magnetically attached to the carrying cylinder. Thus, thecliché blank may comprise a surface layer of photosensitive polymermaterial, but also non-polymeric materials such as ceramic materials andmetals, or any other material allowing similar forming. Polymer clichésare less costly to produce, and thereby particularly suitable forshorter series.

Preferably, the rolls 4, 5, 7, 17 and 16 are journalled in fixedbearings on a stand or baseplate 18, cf FIG. 3, while the milling cutter8 is movable arranged in a direction to or from the patterned cylinder 7in order to widen or shorten said nip 6, illustrated by a double arrow19. As an alternative the milling cutter 8 is stationary and, thus, thepatterned cylinder 7 is movable. Additionally, the second support roll17 may be movable arranged in order to increase or decrease the webtension rapidly. This is accomplished by means of one or more motors 21,e.g. an electrical linear motor. The motor 21 is via an electricalcircuit 22 connected to a number of sensor means 23, 24, e.g.photo-electric tubes, as will be described more in detail later in thisdescription. Said motor 21 is securely fixed on the stand 18 and drivesin a linear way a projecting rod 25, a free end of which carries a shaft26 supporting the cutting cylinder 8. When the diameter of the cuttingcylinder is smaller than that of the patterned cylinder it is preferredto adjust the position of the cutting cylinder instead of the positionof the patterned cylinder, but this is arbitrary. However, the diameterof the cutting cylinder may be equal to the diameter of the patternedcylinder.

When material with a thickness of a few micrometers is to be cut, thedistance between the cutting tool and the material support is critical.The distance between the tools determines the cutting depth and therebythe quality of the product. To keep the cutting depth constant it isessential to measure and control the distance between the tools. Themeasurement of the distance is very complex since the tools are movingand have a complex structure.

Referring now to FIGS. 2, 5 and 6 a way of precisely adjusting themilling of the web 1 is illustrated. Outside the patterned regions ofthe patterned cylinder 7 a first annular projection or ring 27, actingas a reference ring, is integrated in the envelope surface 11,preferably at both of the ends of said cylinder and concentric to saidsurface. The annular projection 27 is etched, embossed or engraved inthe envelope surface. The radius of the annular projection, r₁, is thesame as or a few μm smaller than the radius of the envelope surface,r_(e), that is r_(e)≧r₁. However, it is envisaged that r₁, in somespecial cases, could be larger than r_(e) that is r₁≧r_(e). The layer 2of metal or conducting material is running on the patterned cylinder 7facing the cutter cylinder 8. In the milling operation by the cuttercylinder said layer 2 in contact with the non-machined regions of theenvelope surface 11, i.e. the ridges 13, are removed leaving the backinglayer 3 exposed in said regions, but not or substantially not abraded bythe cutter cylinder. When the cutter cylinder reaches the interface, orjust has passed it, the part of the metal layer in contact with the topportion of said first annular projection 27 will be removed as well,creating a metalless track 29 in the processed web 10 parallel to itssides, cf FIG. 6. The parts of the metal layer positioned in therecesses and in the grooves 31 defining said annular projection(-s) aremaintained, completely or partly, depending on their configuration.

Said track(-s) 29 or absence of track(-s), resp., are detected by firstsensor means 23 positioned downstream said nip 6 and in a position overthe processed web 10 corresponding to the position of the annularprojection(-s) 27 at the sides of the running, thus processed web 10.The first sensor means 23 sends signals to said circuit 22 commandingsaid motor 21 to extend or retract the cutter cylinder 8 to adjust orretain the size of the nip. If no track 29 is detected by the sensormeans the nip 6 will be shortened or diminished.

As stated above the track(-s) 29 indicates that the nip is too wide oraccurate. However, it does not indicate that the size of the nip is toosmall, i.e. that the cutter cylinder 8 also mills the backing layer 3.This is perhaps allowable in some cases but as a rule only in a smallextent. In order to get an indication when and if too much of theexposed backing layer is removed, i.e. that the size of the nip 6 is toosmall, a second annular projection or ring 32, acting as a referencering, is integrated in the envelope surface 11 of the patterned cylinder7, preferably at both ends of the cylinder, concentric to the firstannular projection 27 (and the envelope surface 11) and at a distance tothe first projection. Preferably, this second annular projection 32 isprovided between the first annular projection 27 and the end of thecylinder, c.f. FIG. 7. The second annular projection 32 is etched,embossed or engraved in the envelope surface in the same way as thefirst annular projection 27 is but has a radius r₂ which is smaller thanthat of the first one, r₁ (r₁>r₂). However, it is envisaged that r₂, insome special cases, could be larger than said radius of the envelopesurface, r_(e), that is r₂>r_(e). The thickness of the backing layer tis larger than the difference of said radii, i.e. t>r₁−r₂.

In the milling operation, and after having removed said ridges 13 andthe part of the metal layer 2 in contact with the top portion of thefirst annular projection 27, the cutter cylinder 8 possibly startsmilling the backing layer 3. When, and if, the thickness of the layerhas decreased to a specific thickness the part of the metal layer 2 incontact with the top portion of said second annular projection 32 willbe removed as well creating a second metalless track 33 in the web,parallel to said first track 29 and the sides of the processed web 10,see FIGS. 7 and 8. The presence of this second track 33 is detected bysecond sensor means 24 positioned downstream said nip 6 and in aposition over the processed web 10 corresponding to the position of thesecond annular projection(-s) 32 at the sides of the running, thusprocessed web 10. Then, the second sensor means 24 sends associatedsignals to said circuit 22 commanding said motor 21 to retract thecutter cylinder 8 to widen said nip 6.

Above, two (pairs of) annular projections, having a radius r₁ and r₂,resp., have been presented. It is of course possible, and in somecircumstances needed, to provide more annular projections, e.g. one witha radius equal to or a few μm larger than the radius of the envelopesurface, r_(e), minus the total thickness of the web 1.

Further, the web has been presented as consisting of one or more layersof conducting material and one or more layers of dielectric material. Itwill however be recognized by a person skilled in the art that presentinvention also can be applied to webs without any conducting layer or inwhich all layers are conductible. Likewise, said layers of the web mayall be made of non-conducting material having different properties. Inorder to use said reference ring technology the involved layers have toexhibit different surface reflectances or transparency.

Above the sensor means has been presented as photo-electric tube orsimilar means. It can also be provided as a transmitter arranged underthe running processed web cooperating with a receiver arranged over theweb, and vice versa. Besides, the sensor means can also be constructedas a unit comprising a pair of separated sliding contacts measuring theresistance of the track.

In the following, five alternative methods of measuring and controllingthe distance between the patterned cylinder 7 and the cutting cylinder 8will be outlined.

A first method includes keeping those machine components whosetemperature induced expansion or shrinking may affect the distancebetween the cylinders 7, 8 at a constant, and possibly the same,temperature. Hence one or more parts of the machine may be provided withper se known cooling and/or heating means.

A second method comprises providing a raster-like patterned area (alsoknown as screen pattern or raster pattern) on the web, e.g. as isdiagrammatically illustrated in FIG. 9 a. The patterned area may beprovided by arranging a set of ridges 41 a, 41 b substantially as shownin FIG. 9 a, such that they form a two-dimensional pattern on the web.The ridges may have an arbitrary profile, as is schematicallyillustrated by the profiles 42 a, 42 b in FIG. 9 a. The ridges may bearranged such that the distance between the cylinders 7, 8 and themilling depth resulting thereof is dependent on the density of thepatterned area. Thus, the patterned area may be evaluated in terms ofdegree of coverage (density), analogous to what is known fromtraditional printing. More particularly, the size of the areas 43 a, 43b, 43 c, 43 d between the ridges, which are of a different material thanthe cut away portions at the ridges 41 a, 41 b, will be dependent on thedepth of the cut and thereby to the distance between the cylinders 7, 8.

As another option, indicated in FIG. 9 b, the patterned area may beprovided in the form of two or more parallel ridges, which whensubjected to the cutting action will result in two or more parallelgrooves 48 a, 48 b in which the conducting material has been removedwith an interjacent strip 49 of non-removed conducting material.Depending on the cutting depth, the with of the grooves 48 a, 48 b andthe strip 49 will vary, thereby giving rise to a measurable variation inthe resistance or enabling galvanic measurement.

Alternatively, the resistance of the pattern may be measuredgalvanically or by measuring eddy currents. Basically, the deeper thepattern, the higher the resistance and the lower the density.

Such patterned control areas may be provided as e.g. small dots ormeander-like patterns, at several places in the overall pattern, e.g. inorder to control a plurality of cylinder arrangements.

A third method comprises use of machine vision systems, where a cameracaptures images of the milled web and compares these with a referenceimage. The vision system may also be used in evaluating the patternedarea as described with reference to FIG. 9 a.

A fourth method comprises measuring the resistance or capacitancebetween the cylinders 7, 8.

A fifth method comprises measuring induced currents in the cylinders 7,8. Such induced currents may arise since the patterned cylinder 7comprises magnets for holding the cliché. Since the cylinders rotaterelative each other, currents are induced in the cutter cylinder 8,which currents are dependent on i.e. the distance between the rolls.

It is realized that all of the above described measurement techniquesmay be used to provide feedback for adjusting, automatically ormanually, the cylinders 7, 8.

In the following, different aspects of the patterned cylinder 7 will bediscussed.

It is recognized that use of a patterned cylinder may in general besuitable for producing endless patterns, i.e. patterns which repeatthemselves with a period being equal to the circumference of thecylinder. However, when providing the patterned cylinders as discussedabove, it is common to prepare a cliché sheet through etching or otherknown techniques. The cliché sheet is mounted on a roll to provide thepatterned cylinder 7. Hence, there is a problem in that there will be ajoint or gap where the ends of the cliché sheet attached to the rollmeet.

A first alternative for addressing this problem is to adapt the patternsuch that a minimum amount of passages are found where the joint is tobe, whereby material is added chemically or through soldering/weldingafter the cliché sheet has been mounted on the roll, thereby building upthe pattern in the area of the joint after the cliché has been mountedon the roll.

A second alternative is to cut the cliché sheet to the exact rightlength, and such that the cut has the right profile, bearing in mindthat the outer part of the cliché, when mounted on the roll, will have aslightly larger circumference than the inner part of the cliché, closestto the surface of the roll. Hence, the cutting profile of the clichésheet will have to be adapted such that its patterned surface isslightly longer than its non-patterned surface.

A third alternative is to pattern the surface of the cylinder, e.g.through milling, etching, embossing or similar methods. Alternatively,the surface of a cylinder shell may be patterned using any of thesemethods.

A fourth alternative is to use separate rings that are arranged adjacentto each other such as to have a common central line. This method isparticularly suited for creating endless lines, and may be combined withany of the methods described above for that purpose.

Furthermore, methods of creating vias, i.e. holes through the entire webare provided.

According to a first method, a ridge on the patterned cylinder 7 is madehigher than the remainder of the pattern, such that the milling actionon the web causes both or all layers of the web to become pierced.

According to a second method, the web may be subjected to more than onemilling action, whereby each subsequent milling action is arranged tocut to a larger depth than the foregoing one. This may be achievedeither by allowing a portion of the web to pass a cutting cylindermultiple times or by arranging multiple cutting cylinders/patternedcylinders after each other.

Optionally, deeper recesses, such as vias or through holes may beprovided in a first cutting step, whereby more shallow recesses areproduced subsequently.

The via may be filled with a functional material, such as a conductingmaterial, e.g. a conducting polymer, a metal or carbon, so as to createan electrical connection through the web. The conducting material may beprovided by means of a printing operation.

It is realized that this technique may be used for creating vias throughthe entire thickness of the web or through one or more layers thereupon.

Preferably, when multiple layers are to be aligned with each other, thesystem is register-controlled.

FIGS. 10 a-10 c are schematic sectional views in a plane substantiallyperpendicular to a main plane of a web comprising a first layer 44 and asecond layer 45, showing a profile of border portions that are to formthe border between unremoved parts of the first, upper layer 44 and theexposed portion of the second, lower layer 45. In FIGS. 10 a-10 c, thecutting direction is indicated by reference numeral ‘M’. Hence, therespective first border portion 46 a, 46 b, 46 c is that border portionwhich is created first. The profiles described with reference to FIGS.10 a, 10 b are a consequence of the operation of the system describedherein, since the web is bent or curved around the ridges (reliefpattern) of the patterned roll 7, while the cutting operation takesplace along a substantially straight line C (FIG. 11), which cuts offthe parts of the web that are elevated by the ridges.

FIG. 10 a shows a simplified view of a profile that may be achievedthrough the present invention. It is noted that since the web isflexible and thereby is bent or curved (FIG. 11) over the protrudingportions of the cliché/patterned cylinder 7, the first, upper layer 44will be tapering in thickness throughout the respective border portion46 a, 47 a, towards the exposed portion of the second, lower layer 45.In one embodiment (not shown), the second border portion 47 a presents asteeper inclination than the first border portion 46 a.

FIG. 10 b shows a more detailed (though exaggerated) view of the profilethat may be achieved by the present invention. In FIG. 10 b, the firstand second border portions 46 b, 47 b are slightly curved due to thecurvature of the flexible web in connection with its forming. Also, inFIG. 10 b, the second border portion 47 b is generally steeper than thefirst border portion 46 b.

Hence, as shown in FIGS. 10 a and 10 b, at the border portions 46 a, 47a; 46 b, 47 b, as seen in a plane that is substantially perpendicular tothe main plane of the laminated sheet, the thickness of the first layer44 is continuously tapering from a point where the first layer 44 issubstantially unremoved to a point where the second layer 45 is exposed.

This type of border portions may be achieved by the above describedmethod on any type of (preferably very thin) laminated sheet material,and in particular on laminated sheets comprising at least one layer ofconducting material laminated on a flexible backing layer ofdielectrical material. It is noted that the described type of borderprofile may be achieved by techniques such as milling, grinding or lasercutting.

For reference purposes, FIG. 10 c shows a profile that would typicallybe obtained through prior art techniques involving etching.

The system and method described above is suitable for incorporation in aprinting system for providing a printed pattern on a surface of a sheetof material, so as to constitute an on-line system together with e.g. aprinting press, whereby the sheet of material is passed through anarbitrary number of subsequent printing and milling steps.

The printed pattern, as well as one or more of the laminated layersprovided may be decorative layers and/or functional layers, as definedabove.

Compared with prior art etching techniques, the system and methoddescribed herein are capable of operating at feed rates in the order ofgeneral printing machinery, whereas etching techniques normally operateat lower feed rates.

Also, this creates the opportunity of providing printed or patternedorganic electronics, solar cells, displays, heaters, antennae etc. It isalso realized that one or more steps of printing may be performed with aview to applying a conductive material, such as a conductive polymer tothe sheet material. Naturally, it is also possible to provide ornamentalpatterns to the sheet of material.

Finally, it is realized that the above described system and methods arenot limited to two-layer webs, but are suitable for webs having anynumber of layers, such as functional layers, insulating layers, carrierlayers and decorative layers, and where one or more layers are to be atleast partially removed so as to expose parts or all of underlyinglayers. In particular, the invention may be used for webs or sheetshaving several functional layers as well as several dielectric layers.

It is also possible to arrange several cutting steps sequentially,Either to operate on the same face of the web or sheet, or to operate ondifferent faces of the web or sheet.

1. A method for manufacturing of electrical components on at least oneof a continuous web and discrete sheets of dielectric material, themethod comprising: feeding, from a supply roll of at least one of alaminated web and a supply of sheets, including at least one layer ofconducting material laminated on a flexible backing layer ofdielectrical material, said at least one of laminated web and discretesheets to a nip between a patterned cylinder and a cooperating cylinder,to shape said conducting layer into a repeated pattern of conductingmaterial having ridges and valleys; and removing, by mechanicalmachining, conducting material from said thus shaped conducting layer,the removing being performed simultaneously with the feeding to shapethe conducting layer, and by way of said cooperating cylinder designedas a milling cutter cylinder.
 2. A method according to claim 1, whereinall of the conducting material in said ridges of the patternedconducting layer is removed.
 3. A method according to claim 1 whereinthe patterned cylinder is rotated with a periphery velocity equal to thefeeding velocity of said laminated web and wherein the cutter cylinderis rotated in a direction contrary to that of the patterned cylinder. 4.A method according to claim 1 wherein the patterned cylinder is rotatedwith a periphery velocity equal to the feeding velocity of saidlaminated web and wherein the cutter cylinder is rotated in the samedirection as that of the patterned cylinder and with a peripheryvelocity substantially faster than that of the patterned cylinder.
 5. Amethod according to claim 1, wherein both the backing layer and theconducting layer are shaped into said repeated pattern.
 6. A methodaccording to claim 5, wherein parts of the backing layer are removed aswell.
 7. A method according to claim 1, wherein said backing layerhaving said manufactured electrical components, is wound to a componentroll for further processing.
 8. A method according to claim 1, whereinthe backing layer having said manufactured electrical components is cutinto sheets.
 9. A method according to claim 1, wherein the size of saidnip is accurately controlled by use of at least a first annularprojection integrated in the envelope surface of said patternedcylinder, at both of its ends and concentric to said surface, the firstannular projection having a radius r₁ and said envelope surface having aradius r_(e), whereby, in said milling operation, the conducting layerof the laminated web in contact with the top portions of the firstannular projection is removed simultaneously with the removal of theconducting layer from said ridges or at an infinitesimal diminution ofsaid nip proving a track without conducting material in the web at bothsides of the web, at least one of said tracks and absence of tracks isdetected by a first sensor means sending associated signals to anadjusting device which, as a response to said signals, adjusts thedimension of said nip.
 10. A method according to claim 9, wherein theadjusting device, when absence of tracks is detected, diminishes saidnip.
 11. A method according to claim 9 wherein a second annularprojection is integrated in the envelope surface of said patternedcylinder, at both of its ends and concentric to said surface, and at adistance to said first annular projection, said second annularprojection having a radius r₂, r₁>r₂, and r₁−r₂<the thickness t of saidbacking layer, whereby, in said milling operation, the conducting layerof the web in contact with the top portions of the second annularprojection could be removed after the removal of the conducting layerfrom said ridges proving a track without conducting material in theprocessed web at both sides of the web, said track without conductingmaterial, if any, are detected by a second sensor device sendingassociated signals to said adjusting if said tracks are present in theprocessed web, to widen said nip.
 12. A method according to claim 1,wherein the size of said nip is accurately controlled by way ofproviding within a predetermined area of at least one of said laminatedweb and sheet, at least two parallel grooves in which the conductingmaterial is removed, said grooves being separated by a strip of saidconducting layer, sensing a resistance of said strip, and sendingassociated signals to an adjusting device which, as a response to saidsignals, adjusts the dimension of said nip.
 13. A method according toclaim 1, wherein the size of said nip is accurately controlled by way ofproviding within a predetermined area of at least one of said laminatedweb and sheet, a raster pattern of said ridges and valleys, sensing saidraster pattern, and sending associated signals to an adjusting devicewhich, as a response to said signals, adjusts the dimension of said nip.14. A method as claimed in claim 13, wherein said sensing is selectedfrom a group consisting of: optical sensing for determining a density ofthe raster pattern, and resistive sensing for determining a resistanceof the raster pattern based on at least one of galvanic and eddy currentmeasurement.
 15. A method for manufacturing of electrical components onat least one of a continuous web and discrete sheets of dielectricmaterial, to the method comprising: feeding, from a supply roll of atleast one of a laminated web and a supply of sheets, including a layerof conducting material laminated on a one flexible layer of dielectricalmaterial, at least one of said laminated web and discrete sheets to anip between a patterned cylinder and a cooperating cylinder, to shapesaid flexible layer into a repeated pattern of flexible material havingridges and valleys, and removing, by mechanical machining, flexiblematerial from said thus shaped flexible layer, the removing beingperformed simultaneously with the feeding to shape the flexible layerand by way of said cooperating cylinder designed as a milling cuttercylinder.
 16. A method as claimed in claim 15, further comprisingreplacing at least some of said removed flexible material with aconducting material, such that a conducting via is provided through theflexible material to the conducting material.
 17. A method as claimed inclaim 15, wherein said replacing is achieved through a printingtechnique.
 18. A device for manufacturing of electrical components on atleast one of a continuous web and discrete sheets of dielectric materialfrom at least one of a supply roll of a laminated web and a supply ofsheets including at least one layer of conducting material laminated ona flexible backing layer of dielectrical material, said devicecomprising: a patterned cylinder; a cooperating cylinder forming a nipinto which at least one of said web and discrete sheets is fed to shapesaid conducting layer into a repeated pattern of conducting materialhaving ridges and valleys; and a device to remove, by mechanicalmachining, conducting material from at least one of the ridges thevalleys of said thus shaped metal layer, said cooperating cylinder beingconfigured as a milling cutter cylinder, to remove conducting materialfrom said conducting layer simultaneously as the conducting layer isforced against the patterned cylinder to shape said repeated pattern.19. A device according to claim 18, wherein said patterned cylinder isrotated with a periphery velocity equal to the feeding velocity of saidweb and wherein the cutter cylinder is rotated in a direction contraryto that of the patterned cylinder.
 20. A device according to claim 18,wherein said patterned cylinder is rotated with a periphery velocityequal to the feeding velocity of said web and wherein the cuttercylinder is rotated in the same direction as that of the patternedcylinder and with a periphery velocity substantially faster than that ofthe patterned cylinder.
 21. A device according to claim 18, wherein, toaccurately control the size of said nip, at least a first annularprojection is integrated in the envelope surface of said patternedcylinder, at both of its ends and concentric to said surface, the firstannular projection having a radius r₁, and said envelope surface havinga radius r_(e), whereby, in said milling operation, the conducting layerof the web in contact with the top portions of the first annularprojection is removed simultaneously with the removal of the conductinglayer from said ridges or at an infinitesimal diminution of said nipproving a metal-less track without conducting material in the processedweb at both sides of the web, wherein a first sensor is arranged at bothsides of the processed web and downstream the nip to detect at least oneof said track and absence of track, and to send associated signals to aadjusting device which, as a response to said signals, is arranged toadjust the dimension of said nip.
 22. A device according to claim 21,wherein the adjusting device, when absence of tracks is detected, isarranged to diminish said nip.
 23. A device according to claim 21,wherein a second annular projection is integrated in the envelopesurface of said patterned cylinder, at both of its ends and concentricto said surface, and at a distance to said first annular projection,said second annular projection having a radius r₂, r₁,>r₂, and r₁−r₂<thethickness t of said backing layer, whereby, in said milling operation,the conducting layer of the web in contact with the top portions of thesecond annular projections could be removed after the removal of theconducting layer from said ridges proving a track without conductingmaterial in the processed web at both sides of the web, wherein a secondsensor device is arranged at each side of the processed web anddownstream the nip to detect said track without conducting material, ifany, and to send associated signals to said adjusting device, if saidtrack is present in the processed web, to widen said nip.
 24. A deviceaccording to claim 18, wherein, to accurately control the size of saidnip, said patterned cylinder is designed to provide, within apredetermined area of said at least one of laminated web and sheet, atleast two parallel grooves in which the conducting material is removed,separated by a strip of said conducting layer, whereby at least onesensing device is arranged downstream the nip to measure a resistance ofsaid strip, and to send associated signals to an adjusting device which,as a response to said signals, is arranged to adjust the dimension ofsaid nip.
 25. A device according to claim 18, wherein, to accuratelycontrol the size of said nip, said patterned cylinder is designed toprovide, within a predetermined area of said at least one of laminatedweb and sheet, a raster pattern of said ridges and valleys, whereby atleast one sensing device is arranged downstream the nip to sense saidraster pattern, and to send associated signals to an adjusting devicewhich, as a response to said signals, is arranged to adjust thedimension of said nip.
 26. A device as claimed in claim 25, wherein saidat least one sensing device is selected from a group consisting ofoptical sensing means for sensing the density of the raster pattern, andresistance sensing means for sensing the resistance of the pattern bygalvanic or eddy current measurement.
 27. A device according to claim18, wherein the patterned cylinder, for providing the relief pattern,presents a surface layer of polymer.
 28. A device according to claim 21,wherein said polymer is at least one of a cured and curable polymer. 29.A cliché for use in the device according to claim 18, including asurface layer of polymer, which is adapted for providing a reliefpattern.
 30. A cliché blank for providing the cliché of claim 29,including a surface layer of polymer, which is adapted to be formed intoa relief pattern.
 31. A printing system for providing a decorative orfunctional printed pattern on a surface of at least one of a continuousweb and discrete sheets of material, at least one of said continuous weband discrete sheets being supplied substantially continuously from atleast one of a supply roll of a continuous web and a supply of discretesheets, wherein said system further comprises the device of claim 12.32. A method for patterning at least one of a continuous web anddiscrete sheets, the method comprising: feeding said at least one ofcontinuous web and discrete sheets from at least one of a supply roll ofcontinuous web and a supply of discrete sheets, the at least one ofcontinuous web and discrete sheets including a first layer of a firstmaterial, and a second layer of a second material, said first layerbeing laminated on said second layer, at least one of said continuousweb and discrete sheets being fed to a nip between a patterned cylinderand a cooperating cylinder to shape said first layer into a repeatedpattern of said first material having ridges and valleys; and removing,by mechanical machining, said first material from said thus shaped firstlayer, the removing being performed simultaneously with the feeding toshape the first layer and by way of said cooperating cylinder, designedas a milling cutter cylinder.
 33. A method as claimed in claim 32,wherein at least one of said first and second layers is a functionallayer.
 34. A device for patterning at least one of a continuous web anddiscrete sheets, the device comprising: means for feeding said at leastone of continuous web and discrete sheets from a supply roll of at leastone of continuous web and a supply of discrete sheets, the at least oneof continuous web and discrete sheets comprising a first layer of afirst material, and a second layer of a second material, said firstlayer being laminated on said second layer; means for feeding at leastone of said continuous web and discrete sheets to a nip, between apatterned cylinder and a cooperating cylinder, to shape said first layerinto a repeated pattern of said first material having ridges andvalleys; and means for removing, by mechanical machining, said firstmaterial from said thus shaped first layer, said cooperating cylinderbeing designed as a milling cutter cylinder, arranged to remove saidfirst material from said first layer simultaneously with the shaping ofthe first layer.
 35. A device as claimed in claim 34, wherein at leastone of said first and second layers is a functional layer.
 36. At leastone of continuous web and discrete sheet, comprising: a first layer of afirst material; and a second layer of a second material, said firstlayer being laminated on said second layer, a portion of said firstlayer being removed so as to expose a surface portion of said secondlayer, such that a border portion is formed at the transition between anunremoved portion of the first layer and an exposed portion of thesecond layer, at said border portion, as seen in a plane that issubstantially perpendicular to the main plane of the laminated sheet,the thickness of the first layer being continuously tapering from apoint where the first layer is substantially unremoved to a point wherethe second layer, is exposed.
 37. The at least one of continuous web anddiscrete sheet as claimed in claim 36, wherein an exposed portion of thesecond layer, as seen in the plane that is substantially perpendicularto the main plane of the laminated sheet, presents first and secondborder portions, and wherein said second border portion tapers moresteeply than said first border portion.
 38. The at least one ofcontinuous web and discrete sheet as claimed in claim 36, wherein saidlaminated sheet comprises at least one layer of functional materiallaminated on a flexible backing layer.